Methods and systems for transporting loads

ABSTRACT

A novel transport pallet ( 1 ) has an inclined load bed that extends from a low end to a high end. A vehicle ( 15 ) is driven onto the pallet  1  from the low end, which is close to the ground. As the pallet ( 1 ) is longer than the vehicle ( 15 ) carried on it, the gradient of the load bed is small as compared to conventional loading ramps. Thus, there is very little risk of the vehicle ( 15 ) grounding as it is driven onto the load bed. The vehicle ( 15 ) is secured to the load bed by tie-down points around the load bed. A forklift truck lifts the pallet ( 1 ) by engaging its forks within recesses at the high end. The truck then places the pallet ( 1 ), low end leading, into a shipping container ( 14 ), lowers the pallet ( 1 ) so that it rests on the floor of the container ( 14 ), and disengages from the pallet ( 1 ). Thus, the vehicle ( 15 ) is housed safely within the container ( 14 ), with little risk of damage during shipping.

The present invention relates to methods and systems for transporting loads and is concerned particularly, although not exclusively, with pallets for use in shipping containers.

Many loads are transported these days in shipping containers, which provide a relatively secure way of carrying cargo. They can be loaded at one location, securely locked, transported great distances by road, rail and sea, and unloaded at another, remote location. Shipping containers tend to be of standard (ISO) dimensions, so that they can be readily transferred from one transport system (e.g. road) to another (e.g. sea). Every day, many thousands of shipping containers are transported around the world.

Shipping containers may provide a relatively safe way of transporting vehicles, particularly those of significant value. It is important to ensure that vehicles can be loaded into and out of shipping containers without damage and that, whilst in shipping containers, they are secured against movement with respect to the container that could cause damage to the bodywork of the vehicle. Many high-value vehicles have low ground clearance, which can lead to expensive damage if the vehicles are driven into and out of containers or other load carriers over quite small obstructions.

Transport pallets are used frequently in shipping containers. Conventionally, a pallet is a portable platform on which goods can be moved, stacked, and stored. Conventionally, the platform provided by the pallet is horizontal, since it is naturally desired to stack goods on it without them falling over. In the vast majority of cases, pallets are made of wood such that they may be reused as often as possible and, when at the end of their useful life, easily disposed of or recycled. However, pallets can be of other materials and of various sizes and shapes.

It is conceivable to transport a vehicle on a suitably large pallet and there have been various proposals to this end. However, there remains the potential problem of loading the vehicle onto the pallet without damage and then loading the pallet into and removing it from a shipping container. For example, US 2007/0017421 shows a transport pallet with spaced apart travel tracks that provide support surfaces that are substantially horizontal, as convention dictates. To load the transport pallet, detachable ramps are provided such that a vehicle may be driven up the ramps and onto the travel tracks (horizontal support surfaces). Particularly as the ramps are relatively short, their gradients are relatively steep, which leads to the risk of a valuable vehicle ‘grounding’ at front or rear as it travels up the ramps and/or passes over the apex between ramps and horizontal tracks. This problem is common to many ramps that have been proposed to allow vehicles to enter shipping containers or the like.

Preferred embodiments of the present invention aim to provide methods and systems for transporting loads that may be generally improved in the foregoing respects.

According to one aspect of the present invention, there is provided a transport pallet comprising a base that rests on a substantially horizontal surface in use, the pallet further comprising an elongate load bed supported on the base, wherein the load bed is inclined to the horizontal surface to provide a high end and a low end that is close to the horizontal surface in use, relative to the high end, the pallet further comprising tie-down means for use in tying down a load supported on the load bed.

Preferably, the inclined load bed has a substantially constant gradient from said low end to said high end.

Preferably, the transport pallet is provided with recesses to receive the forks of a forklift device at or adjacent said high end of the load bed, with the forks extending longitudinally of the load bed.

The transport pallet may also be provided with recesses to receive the forks of a forklift device along or adjacent at least one side of the load bed, with the forks extending transversely of the load bed.

Preferably, towing points are provided at or adjacent at least one end of the pallet, to facilitate towing of the pallet.

Preferably, said base comprises a pair of spars extending longitudinally of the load bed, at or adjacent respective sides of the load bed.

Preferably, said base further comprises a central spar extending longitudinally of the load bed, substantially centrally of the load bed.

Preferably, said base and load bed are of wood.

Preferably, the load bed is reinforced by lengths of metal of angle section, secured at edges of the load bed.

Preferably, said tie-down means comprises holes formed in the load bed, with bars extending across the holes to provide anchoring points for tie-down straps.

Preferably, the load bed has a length in the range 500 to 600 cm and a width in the range 180 to 250 cm.

Preferably, in use of a transport pallet according to any of the preceding aspects of the invention, said high end of the load bed has a height above said horizontal surface in the range 15 to 40 cm and said low end of the load bed has a height above said horizontal surface of up to 10 cm and preferably in the range 2 to 7 cm.

The invention extends to the combination of a transport pallet according to any of the preceding aspects of the invention and a shipping container into which the transport pallets fits.

Preferably, such a combination further comprises a load tied down to said load bed by said tie-down means, the pallet being located in the shipping container with the low end of the load bed leading.

Preferably, said load is a vehicle.

In another aspect, the invention provides a method of transporting a load on a transport pallet having a base that rests on a substantially horizontal surface, the pallet further comprising an elongate load bed that is supported by the base and inclined to the horizontal to provide a high end and a low end that is close to the ground, relative to the high end, the method comprising the steps of placing a load on the load bed and placing the load in a shipping container

Preferably, the load is placed in the shipping container with the low end of the load bed leading.

Preferably, a method as above includes the further step of tying down the load to the load bed.

Preferably, said step of placing the load in a shipping container is carried out by a forklift device that engages the pallet at or adjacent said high end of the load bed.

Preferably, said load is a vehicle and said step of placing the load on the load bed comprises driving the vehicle onto the load bed from said low end.

Preferably, said vehicle is heavier towards one end than the other and said one end is disposed towards said high end of the load bed.

The invention also extends to a load carried on an inclined load bed that is removably installed in a shipping container.

For a better understanding of the invention, and to show how embodiments of the same may be carried into effect, reference will now be made, by way of example, to the accompanying diagrammatic drawings, in which:

FIG. 1 is a perspective view of a novel transport pallet;

FIG. 2 is a plan view of the pallet;

FIG. 3 is a side view of the pallet;

FIG. 4 is a perspective view of a shipping container, with a novel transport pallet inside it and a vehicle secured on the pallet;

FIG. 5 is a perspective view of an alternative spar;

FIGS. 6 and 7 are respectively perspective views from above and below of an alternative pallet; and

FIG. 8 is a view similar to that of FIG. 7, showing a pallet that is generally similar but has optional wheels.

In the figures, like references denote like or corresponding parts.

The novel transport pallet 1 forms part of a novel transport system when used in conjunction with a shipping container 14, as illustrated in FIG. 4. Unlike conventional pallets, the transport pallet 1 has an inclined load bed 3 that extends from a low end 4 to a high end 5. The low end 4 is close to the ground in use, relative to the high end 5.

The load bed 3 is supported on a base 6 that comprises a pair of spars 61 extending longitudinally of the load bed 3, adjacent respective sides of the load bed. The base 6 further comprises a central spar 62 that extends longitudinally of the load bed 3, substantially centrally of the load bed. At the high end 5 of the load bed 3, the ends of the spars 61, 62 are connected by an anti-tip bar 63 that extends from one side of the load bed 3 to the other.

Tie-down points 7 are provided around the periphery of the load bed 3.

At about 30 cm from the high end 5 of the load bed 3, each of the side spars 61 is formed with a pair of eyelets 8, through which a towing rope or cable may be fed.

The pallet 1 may be made of any desired materials. However, in an advantageous embodiment that provides a good compromise between strength, longevity and cost, the load bed 3 comprises three layers of 18 mm exterior grade plywood (WBP—Weather and Boil Proof) glued together with PVA (PolyVinyl Acetate) adhesive to give an overall thickness of about 54 mm. The layers of plywood are also screwed to each other and to the side and central spars 61, 62, which are of timber (e.g. treated softwood) and have dimensions of approximately 225 mm height×75 mm width at the high end 5, the height tapering uniformly to about zero at the low end 4. The eyelets 8 may be lined with e.g. steel tube of 42 mm outer diameter. The thickness of the plywood may also taper towards the low end 4.

The sides of the load bed 3 deck are reinforced by two stiffeners 9, each comprising a length of angle iron of approximately 110 mm×65 mm section. The stiffeners 9 run longitudinally of the load bed 3 with the 65 mm section above the plywood and the 110 mm section offering protection to the edges, in the form of an inverted L. The stiffeners 9 are bolted to the plywood with M10 10 mm bolts at or around 300 mm centres and substantial washers (e.g. 50 mm sq) to the underside of the plywood to inhibit pull-through of nuts on the end of the M10 bolts. As an alternative to the washers, a further length of 50 mm×50 mm angle iron may be provided on the underside of the load bed 3, to receive the ends of the M10 bolts.

In a similar manner, a stiffener 10 at the high end of the load bed 3 comprises a length of angle iron of approximately 50 mm×50 mm section, extending laterally of the load bed 3. Like the stiffeners 9, the stiffener 10 is secured to the plywood in the form of an inverted L. A further lateral stiffener 11, comprising a length of angle iron of approximately 50 mm×50 mm section, is provided at the low end 4 of the load bed, but is disposed the other way up, in the form of an upright L, with one section extending along the edge of the load bed 3 and the other section along the underside of the load bed, to offer some protection to the underside of the load bed 3 where it meets the ground.

To reinforce the underside of the load bed 3, a transverse load spreading plate 12 of 4 mm plate steel measuring approximately 1460×300 mm is provided underneath the load bed 3 with a centre line at approximately 2.4 m from the high end 5, to inhibit forklift tips penetrating the plywood deck.

To reinforce the upper side of the load bed 3, two tracks 13 of 4 mm plate steel are secured to the plywood deck, to receive vehicle wheels. The upper surface of the tracks 13 may have a surface pattern (e.g. checker plate design) to facilitate grip of vehicle tyres.

In the illustrated example, twenty-two tie-down points 7 are provided on the load bed 3, ten along each side and two along the high end 5. The tie-down points comprise 82 mm holes through which 16 mm bar extends, transversely of the pallet 1. The tie-down holes are inset by 60 mm from the edge of the load bed 3 (101 mm to hole centre from the edge).

In the illustrated example, the overall dimensions of the pallet are 5500 mm length, 2224 mm width, 293 mm height at the high end 5 and 70 mm height at the low end 4. As may be seen in FIG. 2, at the low end 4, the sides of the load bed 3 taper inwardly by about 100 mm each side, commencing about 200 mm from the low end 4, to assist alignment of the pallet 1 when entering a shipping container 14.

In use, the pallet 1 is place on the ground which, for ease of explanation, will be assumed to be horizontal. (For ease of reference, it is assumed throughout this specification that the ground is horizontal and the load bed 3 is inclined relative to the horizontal ground. However, it will be appreciated that the ground may be inclined, in which case the load bed 3 may be more or less inclined in absolute terms.) The spars 61, 62 rest on the ground to support the load bed 3 at its gentle angle of inclination, as illustrated and described above.

A vehicle 15 is then driven onto the pallet 1 from the low end 4. As the pallet 1 is elongate and longer than the vehicle 15 carried on it, the gradient of the load bed 3 is small, as compared to that of conventional loading ramps. Thus, there is very little risk of the vehicle 15 grounding as it is driven onto the load bed 3, even if the vehicle 15 has a very low ground clearance.

The vehicle 15 is driven up the load bed 3 until its heavier end is at or adjacent the high end 5 of the load bed 3. For front-engine vehicles, the heavier end is usually the front end. For rear-engine vehicles, the heavier end may be the rear end, in which case the vehicle may be reversed onto the load bed 3.

The vehicle is then secured to the load bed 3 by means of tie-down straps that engage both the vehicle 15 and the tie-down points 7. Alternatively, any other suitable means may be employed to secure the vehicle on the load bed 3.

A forklift truck then engages and lifts the pallet 1 by engaging its forks within the recesses that are defined at the high end 5 of the load bed 3 between the spars 61, 62 and the anti-tip bar 63. For example, the recesses may have a height of about 160 mm. The forklift truck then places the pallet 1, low end 4 leading, into the shipping container 14, through open doors 16, lowers the pallet 1 so that it rests on the floor of the container 14, and disengages from the pallet 1.

Thus, as illustrated in FIG. 4, the vehicle 15, secured firmly on the pallet 1, is housed safely within the container 14, the doors 16 of which may be closed and locked.

It will be appreciated that the apparatus and methods as illustrated and described above provide many advantages. Firstly, the vehicle 15 may be driven onto the pallet 1 with very little risk of damage. It may be secured to the pallet 1 before the pallet 1 enters the container. There is no need for any personnel to enter the container. Once in the container, in the event of any movement, it is the pallet 1 that will tend to move with respect to the container. Although sides of the pallet 1 may collide with the internal walls of the container 14 as a result of significant motion in transit, the vehicle 15 should remain safely tied down on the pallet 1, with minimal risk of collision with the walls of the shipping container 14.

If the pallet 1 is a close fit within the container 14, there is relatively little room for movement of the pallet 1 in transit. If desired, the pallet 1 may be fitted with means to engage the internal walls of the container 14 and further limit relative movement—for example, rollers that may be deployed and retracted from the high end 5 of the pallet 1.

To retrieve the pallet 1 from the container 14, a forklift device simply engages and lifts the high end 5 of the pallet 1 and removes it from the container. The vehicle 15 can then be quickly untied or otherwise unsecured and driven off the load bed 3—again, with minimal risk of damage from grounding.

Two or more pallets 1 may be disposed end to end in a long shipping container (e.g. a 40 ft=12.2 metre container). A second pallet 1 may engage a first pallet 1 already in the container and push it along the floor of the container, and so on. To retrieve a pallet located more deeply within a container, a rope or cable may be passed through the eyelets 8 in the high ends of the spars 61 and the pallet 1 simply pulled along the floor of the container, like a sled. Once near the doors 16, the pallet 1 can be engaged by a forklift device and lifted out of the container.

The anti-tip bar 63 serves to inhibit tipping of the pallet 1, in the event that the centre of gravity of the pallet is not very close to the high end 5. Any tilting of the pallet 1 on forks of a forklift device will be restricted by the anti-tip bar 63 coming into contact with the undersides of the forks.

Although the illustrated pallet 1 is designed for forklift engagement at the high end 5, it may be possible also to provide recesses to receive the forks of a forklift device along or adjacent the sides of the load bed 3, with the forks extending transversely of the load bed.

Although the illustrated example shows a vehicle on the pallet 1, other loads may also be transported on it.

The load bed 3 and its supporting base 6 may be formed as a single or monolithic structure, rather than having a separate base 6 formed by the spars 61, 62.

As a cheaper ‘disposable’ alternative to that illustrated and described above, the plywood may be cheaper, untreated, shuttering ply, glued and screwed to two side spars 61 of 225 mm maximum height and 50 mm width, without the central spar 62. Instead of the metal anti-tip bar 62, a 1550 mm length of 225 mm×50 mm timber may extend laterally of the load bed 3, secured between the side spars 61. Just eight tie-down holes 7 may be provided, four along each side of the load bed 3.

The alternative, cheaper pallet 1 would have a much shorter life expectancy than the more robust version, but may be perfectly adequate for one-off use, after which it may be recycled, or re-used for lower value loads for as long as it was serviceable.

FIG. 5 shows an alternative to the wooden spars 61, 62. In FIG. 5, the alternative spar 65 is of steel, having a top-hat section that tapers from the high end 5 to the low end 4. Out-turned flanges 66 of the spar 65 are formed with holes 67 to receive bolts that pass through the plywood deck of the load bed 3 and engage with nuts at the underside of the flanges 66.

FIGS. 6 and 7 illustrate an alternative pallet 100 that operates in a manner similar to the preceding embodiments but is of substantially all-steel construction. A further feature of the pallet 100 is that a pair of side-loading fork lift tunnels 130 are provided along its sides (opening into each side) to facilitate handling of the pallet 100—for example, for loading onto flat bed vehicles and trailers.

The base 106 of the pallet 100 may be fabricated largely from standard L and H steel sections, such that it has elongate spars 161 at the sides interconnected by transverse spars 110, 111, 120 at the ends and at intermediate positions along the length of the pallet 100. The construction affords a pair of recesses 101 to receive the forks of a fork lift truck at the high end 5. In use, the forks bear against the underside of one or more of the transverse spars 120 and/or transverse fork lift tunnels 130.

The transverse spar 110 at the high end 5 affords an abutment surface that may be pushed, e.g. by the low end 4 of an adjacent pallet 100, such that a pair of pallets 100 in tandem may be pushed into a container. A pair of towing eyes 108 are provided at the high end 5, for towing the pallet 100.

The load bed 103 comprises a plurality of reinforced steel checker plate deck sections 113. As in the preceding embodiments, numerous tie points 107 are provided for vehicles and cargo. Lifting points 115 are provided for crane operations and are protected by deck blocks 116 that facilitate the stacking of empty pallets 100 on top of one another, without damage to the lifting points 115. The deck blocks 116 may engage with or adjacent the elongate spars 161 of a pallet stacked above.

In the variant of FIG. 8, a generally similar pallet 200 does not have side fork tunnels but, as a further option, has rollers or wheels 240, 241 that are provided to facilitate towing of the pallet 200. The front wheels 240 may be castors (freely swivelling) whilst the rear wheels 241 are ‘in line’ with the length of the pallet 200. An A-frame may be attached at the front (high end 5) of the pallet 200 such that the pallet may be towed.

The rear wheels 241 are retractable and the front wheels 240 may also be retractable, such that the pallet 200 may rest on a supporting surface after it has been manoeuvred into a desired position with the aid of the wheels 240, 241. An alternative arrangement would be a pair of steerable wheels located about midway along the length of the pallet 200. Again, such wheels may be retractable.

Preferably, the gradient of the load bed with respect to its base is in the range 2% to 10% and more preferably in the range 3% to 5%.

In this specification, the verb “comprise” has its normal dictionary meaning, to denote non-exclusive inclusion. That is, use of the word “comprise” or any of its derivatives) to include one feature or more, does not exclude the possibility of also including further features.

The reader's attention is directed to all and any priority documents identified in connection with this application and to all and any papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

All or any of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all or any of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings), may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. 

1-24. (canceled)
 25. A transport pallet comprising a base that rests on a substantially horizontal surface in use, the pallet further comprising an elongate load bed supported on the base, wherein the load bed is inclined to the horizontal surface to provide a high end and a low end that is close to the horizontal surface in use, relative to the high end, the pallet further comprising tie-down means for use in tying down a load supported on the load bed, and the inclined load bed having a substantially constant gradient from said low end to said high end.
 26. A transport pallet according to claim 25, provided with recesses to receive the forks of a forklift device at or adjacent said high end of the load bed, with the forks extending longitudinally of the load bed.
 27. A transport pallet according to claim 25, provided with recesses to receive the forks of a forklift device along or adjacent at least one side of the load bed, with the forks extending transversely of the load bed.
 28. A transport pallet according to claim 25, provided with towing points at or adjacent at least one end of the pallet, to facilitate towing of the pallet.
 29. A transport pallet according to claim 25, wherein said base comprises a pair of spars extending longitudinally of the load bed, at or adjacent respective sides of the load bed.
 30. A transport pallet according to claim 29, wherein said base further comprises a central spar extending longitudinally of the load bed, substantially centrally of the load bed.
 31. A transport pallet according to claim 25, wherein said base and load bed are of wood.
 32. A transport pallet according to claim 31, wherein the load bed is reinforced by lengths of metal of angle section, secured at edges of the load bed.
 33. A transport pallet according to claim 25, wherein said tie-down means comprises holes formed in the load bed, with bars extending across the holes to provide anchoring points for tie-down straps.
 34. A transport pallet according to claim 25, wherein the load bed has a length in the range 500 to 600 cm and a width in the range 180 to 250 cm.
 35. A transport pallet according to claim 25, wherein in use said high end of the load bed has a height above said horizontal surface in the range 15 to 40 cm and said low end of the load bed has a height above said horizontal surface of up to 10 cm and preferably in the range 2 to 7 cm.
 36. In combination, a transport pallet according to claim 25 and a shipping container into which the transport pallets fits.
 37. A combination according to claim 36, further comprising a load tied down to said load bed by said tie-down means, the pallet being located in the shipping container with the low end of the load bed leading.
 38. A combination according to claim 37, wherein said load is a vehicle.
 39. A method of transporting a load on a transport pallet having a base that rests on a substantially horizontal surface, the pallet further comprising an elongate load bed that is supported by the base and inclined to the horizontal to provide a high end and a low end that is close to the ground, relative to the high end, the inclined load bed having a substantially constant gradient from said low end to said high end, the method comprising the steps of tying down a load on the load bed and placing the load in a shipping container
 40. A method according to claim 39, wherein the load is placed in the shipping container with the low end of the load bed leading.
 41. A method according to claim 39, wherein said step of placing the load in a shipping container is carried out by a forklift device that engages the pallet at or adjacent said high end of the load bed.
 42. A method according to claim 39, wherein said load is a vehicle and said step of placing the load on the load bed comprises driving the vehicle onto the load bed from said low end.
 43. A method according to claim 42, wherein said vehicle is heavier towards one end than the other and said one end is disposed towards said high end of the load bed. 